MAXI MANUS FITTING INSTRUCTIONS
Identify the awning tracking and fit it to the side of the truck at the pre-determined mounting height. You will have advised us of the mounting height prior to your awning being manufactured/delivered, so make sure you mount the tracking at the specified heights. The heights at the front and back of your vehicle may be different so make sure you mount the tracking at the correct height. Also you will notice that on the Maxi Minus modules over 6mtrs long, the tracking will be in more than one piece. Make sure you fit the tracking in the correct sequence, they will be clearly marked. We strongly recommend you apply a generous amount of polyurethane adhesive/sealant between the aluminium tracking and vehicle body prior to fixing and use a suitable fixing at approximately 200mm centres along the entire length of the tracking.
The mounting brackets have been temporarily drilled and located onto the tracking; make sure you replace these brackets in exactly the same place. We recommend you drill through the body and nut and bolt these brackets. Where access to the vehicle is prohibited we advise you use an alternative fixing material i.e. cavity fix or other. Make sure you place the brackets the correct way up.
Vehicle legs can now be fitted; these should be placed with the keder grove of the vehicle leg in line with the OD of the tracking. Please note: The pair of vehicle legs are the only uprights that have a slotted foot. This slotted foot is to allow for any movement of the vehicle so make sure the slotted foot is in the middle of the slot prior to drilling up for the bosses. Position the two bosses and drill the bodywork. You will need a 5/8th or 16mm hole saw for this process, apply some sealant behind the boss prior to fitting and secure with self tapping screws or rivets.
Storm bars are optional on 2 bay modules but are more or less standard equipment for 3 and 4 modules. You will need to erect the awning before you complete this process. You will notice the side awning rails are pre-drilled approximately in the middle of their length, use this hole to locate the storm bar bracket. Put the storm bar in place and hold it against the side of the truck, make a mark so you can position the boss correctly, make sure you strike a line vertically down for the side awning rail mounting bracket position, align this with your other mark and then fit the boss.
Vehicle tracking is optional on all awnings. If you've ordered a skirt then please refer to your order for mounting heights of this tracking. Rivet or screw the tracking in position at the correct heights.
Your awning should now be ready for full assembly, refer to assembly instructions for this procedure. If you have any parts missing please advise us immediately.
JUMBO CASSETTE FITTING INSTRUCTIONS
Congratulations on purchasing your new jumbo windout awning from The Awning Company. For your own health and safety please read the instructions carefully before starting any installation work.
Your awning has been manufactured and tested at our factory premises, the only adjustment you may need to make is the roof pitch.(There are details on this in section 3).
Tools required
Electric drill, drill bits 4.1, 6.5, 8.5, & pilot bit, Hand riviter, 4mm & 5mm allen key,13mm & 10mm spanner, 17mm socket, Pozi drive screwdriver, string line, sealant & mastic gun.
1. INSTALLATION OF MOUNTING BRACKETS
These brackets are mounted in the format as shown in figure 1. The exact position of these will depend on each individual vehicle. If reinforced points (i.e. metal roll bars) are accessible in the vehicle, the mounting bracket should be fixed through these wherever possible. Where the vehicle is of sandwich construction (inner & outer shell separated by a hollow or insulating material) we would recommend spacers are inserted into the body to prevent crushing when the bolts are tightened.
Please give consideration to the interior of the vehicle when selecting the mounting points. Check to see if they are accessible and do not interfere with any interior fittings.
One of the end mounting brackets should be installed first, this should be then used as a reference point for the following brackets. As shown in figure 2 leave at least 25mm above the bracket to allow room for the cassette to locate. It is useful to use a string line to check the alignment of successive brackets, as this is critical for easy installation of the cassette. Wherever the outer shell of the vehicle is penetrated, a liberal coating of sealant should be applied to prevent an ingress of water entering the vehicle via the fastener.
2. INSTALLATION OF AWNING CASSETTE
Once the mounting brackets are in position, you are ready to load the cassette into place (this will require at least 2 people). When the cassette is in the correct position on the horizontal axis wind out the roof sheet. You can now drill through the hole in the bottom of the mounting bracket through the bottom of the cassette (Dia 6.5mm). Fasten the cassette to the mounting bracket with the M6 button head bolt, nylock nut and washer provided.
3. ADJUSTING THE FACIA HEIGHT (PITCH)
To adjust the roof section to the correct height, the roof should be fully wound out. Remove the plastic end caps from the cassette. This will reveal the end bracket, you will notice two 17mm socket size bolts, slacken these by half a turn. If you now look on the inside of the end bracket where the arm attaches there is a 5mm set screw. Get another person to take the weight of the arm while you either turn the screw in or out to raise or lower the pitch. Do not attempt to use the adjuster screw to raise or lower the arm as this will result in damage to the thread in the adjuster block. Now rewind the roof to check its operation.
INSTALLATION OF TRACKING FOR SIDE SHEETS & SKIRT
Measure and cut tracing to correct size. Ideally on side sheet tracking the tracking should be fixed 25mm inwards from the end of the cassette and fixed at the top under the cassette. We recommend you 'flare out' the tracking approximately 75mm to make it easier to insert side sheet keder. The tracking is best fitted with fixings approximately every 250mm by drilling a 4mm hole. When screwing or riveting we recommend a suitable adhesive/sealant such as sikaflex is used a seal on the rear side of the extrusion once finished fixings can be concealed with rubber infill strip.
Skirt tracking is fitted in the same manner as side tracking. Cut to length 'safe off' ends of tracking by 'flaring' the ends and smoothing off with a file and abrasive paper. Skirt tracking is best fitted flush with the ends of the side sheet tracking ensuring that keder can be inserted. On tracking that is in several pieces at different heights an overlap of 25mm is recommended. Ensure that skirt tracking does not hinder the opening of doors and lockers. If tracking is being fitted to lockers leave approximately 25mm gaps on each locker to make insertion of keder easier.
Clear fitting area required for Jumbo box awning is 300mm (height)
Actual Height of cassette = 240mm
Actual Depth of cassette = 128mm
FRONTIER CASSETTE FITTING INSTRUCTIONS
Tools Required
Electric drill, drill bits - pilot drill, 4.1, 5.1, 8.5mm, Hand rivetor, 5mm allen key, 19mm, 13mm & 10mm spanner, string line, sealant & mastic gun, file and abrasive paper.
For technical assistance contact the Awning Company on 01204 363463/364105
1. INSTALLATION OF STRATFORD BRACKETS
The exact position of these will depend on each individual vehicle. If reinforced points (i.e. metal roll bars) are accessible in the vehicle the mounting bracket should be fitted through these wherever possible. Where the vehicle is of sandwich construction (inner and outer shell separated by a hollow or insulating material) we would strongly recommend that spacer tubes are inserted into the body to prevent crushing when the fasteners are tightened. Please give consideration to the interior of the vehicle when selecting the mounting points. check to see if they are accessible and do not interfere with any interior fittings.
One of the outer stratford brackets should be inserted first: this should then be used as a reference point for the following brackets. Leave at least 25mm above the bracket to allow room for the cassette to locate. It is useful to use a string line to check the alignment of successive brackets, as this is critical for the easy installation and operation of the cassette. Wherever the outer skin of the vehicle is penetrated, a liberal coating of sealant should be applied to prevent an ingress of water entering the vehicle via the fastener.
If the awning is to be semi roof mounted please note that the mounting bracket must be mounted as upright as possible.
2. INSTALLATION OF AWNING CASSETTE
Once the mounting brackets are in position, you are ready to load the cassette into place, (this will require at least two people). When the cassette is in the correct position along the vehicle, you can drill through the bottom of the mounting bracket with a 5.1mm drill bit and secure the cassette with a steel rivet provided.
3. ADJUSTING THE FACIA HEIGHT (PITCH)
This will require two people. To adjust the roof section to the correct height the roof section should be fully wound out. Remove the plastic end caps from the cassette. This will reveal the end bracket, you will notice two 19mm spanner size bolts. Slacken these by half a turn. If you now look at the top head bolt, you will see this passes through an adjusting block. The pitch can now be set by rotating the 13mm headed bolt in or out. A helper must support the arm. Do not attempt to use the adjuster screw to raise or lower the arm. Do not attempt to use the adjuster screw to raise or lower the arm unsupported as this will result in damage to the thread in the adjuster block. When the pitch is set retighten the 19mm bolts and rewind the roof section to check the operation.
4. FIXING OF TRACKING FOR SIDE SHEETS
When fitting the vehicle tracking, its start and finish point will depend on the type and shape of vehicle you have. On flat-sided vehicles such as campers, box vans and trailors, as a general rule the tracking should run 25mm inset from the metal end of the cassette (not the plastic end cap) and have a gap of 80mm below the cassette.
If the vehicle is a panel van or similar, then carefully assess where the tracking can stop and start.
When the tracking has been cut to length ensure that the ends are turned out and all sharp edges are removed.
To attach the tracking to the vehicle drill 4.1mm holes down the length at approximately 200mm hole centres. Again apply sealant wherever the vehicle shell is penetrated. This can now be fitted with the rivets supplied. Apply a dab of sealant over each rivet head. You can now fit the plastic infill tape to cover the rivet heads. You will find this easier to fit if it is soaked in hot water to make it pliable.